Getting closer. Tackling some details. I haven't driven her since we installed the power steering, but I do remember the difficulty of turning the wheel combined with worn out springs for the horn buttons resulted in unintentional honking almost every time I had to take a slow corner. I just fixed the stiff steering with a saginaw box, thought I'd figure out the hair-touch horn buttons too.
I opened it up and all the springs were rusted, two had snapped and were just floating in there. The final one was a few presses away from total failure.
I could not for the life of me find original replacement parts without buying an entire steering wheel with unknown internals.
I got thinking... I need spring steel that would "spring" back to it's original shape each time it's bent. I looked into buying some flat stock spring steel and heat bending it, re-tempering it, etc... I'll be honest, the learning curve sounded crappy and I was talking myself into it. A cop-out would have been to reroute the horn button to an existing button on the shifter knob (more on the shifter another day). I considered that route for a moment, but it was never
REALLY an option for me.
Somewhere along the way I thought of one of those rainbow shaped springs they use for window screens to press them into window frames... So off I went to the Home Depot. They didn't have what I had imagined but they did have these:
A little trial and error and I had a stew going.
1. Drill out single rivet that held the little plastic wheel bracket.
2. Toss bracket and wheel in the garbage. That sparks joy.
3. Drill hole all the way through at "hook" end.
4. Drill mounting hole at appropriate distance for button mounting. (I used rusted OEM piece to measure)
5. Bend new "springs" a bit, by bending them past where you want them to return. (see side view below for where I ended up)
6. Use OEM hardware to attach horn buttons to new "springs".
7. Bolt new assembly to steering wheel.
8. Reassemble steering wheel.
All 3 buttons installed.
Haven't tested horn functionality yet (battery is still disconnected, horns are not wired, etc...) but they are much stiffer (not too stiff) and they make a satisfying click as I tap them against the contact in the wheel (theoretically completing the circuit and sending a tasty "honk" out the bib). They don't have the same lateral stability but the holes the horn buttons sit in should keep them from going askew.
$7 bucks and an hour of futzing around.